1,101

Re: Never before has so little power been made from so much displacement!

so here's the scale of the problem. i thought i would have been able to use the angry hamster box and the current clutch setup. but apparently it's all gone to pot.

here's a new picture of the area in question:
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0118.jpg

and here's a dimensioned drawing of the area
http://frankensteinmotorworks.com/AirplaneMR2/phase2/transfercase%20spacejpg.jpg

in that space, i have to approximately triple the rpm, reverse the rotation and provide a clutch.

currently in the garage, i have four things that may help fill that gap:

1)GM auto 4x4 transfer case
this has a 2.73:1 step up and a clutch in it
it's 9.75" between centers and if the tailshaft is cut out, it would be 13" long
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0119.jpg

2)NP205
1.98:1 between any input and output, more configurable than the gm t-case, all gears instead of a chain.
9.75" between outputs and 16" long using both yokes on opposite sides
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0120.jpg

3) the casale v-drive i originally bought for this project
1.75:1 overdrive or underdrive or anything in between. provides rotation swap. has unfortunate 12 degree angle between shafts. about 6" drop, 9" deep
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0121.jpg
[img]http://frankensteinmotorworks.com/Airpl … _drive.jpg[/img[
(it has the extra 2.73:1 box on it in that pic, but it's easy to remove.)

4)NP203 transfer case. no pic, it uses spur gears for the 1.98:1 low range, might be usefull but not sure enough to bother dragging it out to take a picture.

my thought at the moment is to keep it as simple as possible and as strong as possible. it anyone has any ideas for something that would be a better fit, I'm listening.

1,102 (edited by Junkyard Dog 2012-02-16 07:49 PM)

Re: Never before has so little power been made from so much displacement!

Is there any way you can put the clutch on the engine flywheel? Then you could use a 2 gear case between the clutch and the transmission input shaft. Martin Gear etc make all kinds of spur gears, the case would be merely (yeah, right! sounds so damn easy big_smile) a matter of fabrication.

http://martinsprocket.com/

Another long shot: tilt the engine and transmission 6 degrees each and use the Casale V drive.

Philosophy of life: old age and treachery will ALWAYS overcome youth, enthusiasm and cash. General smartass know it all beer swilling ne'er do well. Avoid eye contact with this person, best avoided completely. 2008 Animal House Racing CMP 'Most Likely To Leave In An Ambulance' 2009 Blind Rodent Racing CMP 2010 Team Galileo CMP 2011 Roundhouse Kick Racing CMP 2012 Road Kill Grill Racing CMP (x2)

1,103

Re: Never before has so little power been made from so much displacement!

Junkyard Dog wrote:

Is there any way you can put the clutch on the engine flywheel? Then you could use a 2 gear case between the clutch and the transmission input shaft. Martin Gear etc make all kinds of spur gears, the case would be merely (yeah, right! sounds so damn easy big_smile) a matter of fabrication.

http://martinsprocket.com/

Another long shot: tilt the engine and transmission 6 degrees each and use the Casale V drive.

putting a clutch there isn't impossible. but it's far from easy. the clutch disk and pressure plate end up needing to be custom items because they need to handle a 4" shaft through the center.

also, there's the issue with not having a bellhousing to push against for the disengaging of the pressure plate.

the transmission and the motor already come within an 1/8" so to tilt them the bottom of the trans would have to go down. it's already impossible to unload from a trailer without the transmission leaving a divot in the grass. there's less than 3" clearance under there, i can't afford to lose more. tilting the motor would certainly be possible. there's no reason i can't other than it would require redoing quite a bit of work that is already done and works well.

I really do think a box with a few gears in it would work well. that Martin place does not do gears that will handle the speed and RPM that i need because it's over their limit of 1000ft/min of pitch speed. plus, having priced out stuff like that before it's a much better idea to scavenge from existing products.

something like this would fit perfectly: http://www.profabmachineinc.com/monster.html it would just be missing the clutch, but i could fabricate something for that (or pull a speedy cop and not put in a clutch at all)

this one would also work: http://www.scsgearbox.com/4x4-transfer-cases.html

but you guys don't want to know what the prices of those things are. it may not blow the judge's budget exempt view of this build's limits. but it blows my personal limits.

the only thing that looks semi-promising right now:
http://frankensteinmotorworks.com/AirplaneMR2/phase2/transfercase-space2.jpg

i'd have to merge the two boxes together. neither of which are expensive enough that i would feel bad welding the two together (the transfer case is cheap and the casale was $200 and available all day long)

i'd likely need to add an oil pump to the whole contraption to bring oil to the casale up top, but that isn't hard. heck, some well placed scrapers would probably do it. the transfer case's chain would pick up plenty of oil i bet.

i even have the tailshaft housing coupler from the GM transmission so i could weld that to what's left of the angry hamster box and the whole thing could hang there. (probably with an extra support rod or two to not snap off the whole thing) then the remaining gap could be bridged with a simple drive shaft.

but i'm not entirely happy with that solution.

Re: Never before has so little power been made from so much displacement!

Might be a little off the wall but how about a tire on the output of your motor running on a small steel drum on the input of the trans?  Like you see on rides at the fair...  Clutch might be a challenge though.  Electric clutch in the wheelhub might get you there.

'Nother thought along the lines of your t-cases: how about running a small trans with reverse gears only?  I have a Toyota Land Cruiser 3sp with a cast iron case that is maybe 10" long not counting shaft stick out.  They're cheap (I have one you can have...) and stand up to V8's without too much issue.  Drive it "backwards" like you're planning with t-cases to get your speed step up.  Shock loading might kill this idea though.

Don't think I have the answer but maybe you might get a kick in the right direction.

Nick
Focke Ewe racing -> Muttonheads! Racing -> Torque Junkies
86ish VW GTI...now with TDI Powah!

1,105

Re: Never before has so little power been made from so much displacement!

The tire "Fair ride" answer would give you the directional reversal, and different tire sizes could help your ratio, The Idea is simple enough, and would probably help your shock load problems. AS for a clutch.... Newer all wheel drive use an electric powered clutch pack on the rear diff. This might be able to be used on the front of the trans.

1,106

Re: Never before has so little power been made from so much displacement!

Mkotzias wrote:

The tire "Fair ride" answer would give you the directional reversal, and different tire sizes could help your ratio, The Idea is simple enough, and would probably help your shock load problems. AS for a clutch.... Newer all wheel drive use an electric powered clutch pack on the rear diff. This might be able to be used on the front of the trans.

the fair ride answer has more side-load than the chain did, that's just not an acceptable answer.

as for the haldex differential, i have one here in the shop i bought just for that purpose. I had forgotten about it in the corner of the garage. it provides a 90* turn and about a 3.5:1 ratio.

you know, when i started this project i really figured "getting a WWII motor back to running order" was going to be the tough part.

1,107

Re: Never before has so little power been made from so much displacement!

With a wider surface wouldn't the side load not be an issue? Let the tire find its center.

1,108

Re: Never before has so little power been made from so much displacement!

Mkotzias wrote:

With a wider surface wouldn't the side load not be an issue? Let the tire find its center.

wider means less psi at the contact patch, but the pressure on the shafts will be the same.

1,109

Re: Never before has so little power been made from so much displacement!

Maybe I just need one of these at each wheel: http://www.surpluscenter.com/item.asp?i … =hydraulic with about a 2.7:1 reducer.

the wheel motors aren't ridiculously priced. but the hydrostatic pump that can handle that kind of HP load is serious coin.

Re: Never before has so little power been made from so much displacement!

If side loading is the issue with the fair ride idea then why not a couple "straps", one on each side of the tire and contact drum, to hold the side load.  Use a couple flexible shaft couplers to connect the rubber OD gearbox to the engine and trans.  Now there's no side load on the engine and trans...still a wacky idea.  I might have the right piece of steel tube in my scrap pile to FWIW...

The straps could be expanded to a couple plates that will also mount the whole rig to the car and of course mount some flanged bearings and so on.

Nick
Focke Ewe racing -> Muttonheads! Racing -> Torque Junkies
86ish VW GTI...now with TDI Powah!

1,111

Re: Never before has so little power been made from so much displacement!

Marc wrote:
Mkotzias wrote:

With a wider surface wouldn't the side load not be an issue? Let the tire find its center.

wider means less psi at the contact patch, but the pressure on the shafts will be the same.

So If I understand right.... Your concern is that the trans and engine centerlines are not staying the same distance away from each other,
How about some sealed bearings and a aligning bracket between the centerlines? I believe a similar idea to zebrabeefj40.

1,112

Re: Never before has so little power been made from so much displacement!

yes, i understand that the carnie ride drive system could be made to work. but ... no.

i have to be able to sleep at night with the decision i made and that's not one i'm willing to make smile

1,113

Re: Never before has so little power been made from so much displacement!

Mkotzias wrote:

The tire "Fair ride" answer would give you the directional reversal, and different tire sizes could help your ratio, The Idea is simple enough, and would probably help your shock load problems. AS for a clutch.... Newer all wheel drive use an electric powered clutch pack on the rear diff. This might be able to be used on the front of the trans.

THANK YOU!

you reminded me that i had previously come up with a decent solution to this.

if i use that haldex diff and a 3000GT transfer case:

http://www.stealth316.com/images/mkxfercase1.jpg

the t-case is a .815:1 ratio and the haldex is 3.749

gives me an overall ratio of close enough to 3 to not matter. and a clutch that is driven by a solenoid. i just need a simple controller to enable clutch-by-wire.

i just need a 3000gt transfer case now. something like this one: http://www.ebay.com/itm/3000GT-Stealth- … 912wt_1397

a little hacking & welding and i'll be in business!

1,114

Re: Never before has so little power been made from so much displacement!

I opened up the haldex to see what’s inside and more importantly, to get the exact gear ratio from it.

The ratio is 41:16 (2.5625) so I’ll use the gt3000 differential as an overdrive instead of under like I thought earlier.

The overall ratio is 3.144 which makes 1950rpm at the engine 6130rpm at the transmission input. Well in the range of where we want to be.


my thought is to hang the haldex so that one of it's outputs is now driven by the radial. this will spin it's internals like it's traveling 140 to 160mph max. a little outside of it's normal range, but i'm sure it's within everything's design parameters.

then, the output of the haldex will go into the gt3000 transfer case's input and the output will drive the transmission's input.

in this configuration the whole assembly is 2.5-4" too long but that can likely be made up with a driveshaft that has a bit of an angle to it.

the other possibility is to put the haldex unit at the bottom as an extension to the transmission's input shaft. this may be easier and the lengths are all kept in check better, but it does mean that the speeds it will be seeing will be closer to 170-195mph range for the haldex box. i'm sure the clutches won't last long at that rate, but i suspect it's doable.

we'll see when the gt3000 box gets here and i can get proper measurements from it.

meanwhile, here are some pictures for everyone's entertainment smile

http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0122.jpg

http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0123.jpg

this is the wet clutch pack:
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0124.jpg

teeth count so you can see which way the gear ratio goes.
http://frankensteinmotorworks.com/AirplaneMR2/phase2/gt3000t-case.JPG

1,115

Re: Never before has so little power been made from so much displacement!

Marc wrote:

this will spin it's internals like it's traveling 140 to 160mph max.

You have options to cool this thing with more than air? Maybe adapt a diff cooler to add some capacity and rid some heat at the same time?

PS- I know a carny wheel setup is not fitting with the cars swagger but I really do dig the whimsy it would add. Not advocating for it, just a comment from the sidelines.

Daniel Sycks
Muttonheads!, nee Focke-eWe190 85-86-87-88 GTI
A Division of Cosworthless Racing. Sponsored by Marlburro!
http://www.facebook.com/pages/Muttonhea … 7122228200

1,116 (edited by Marc 2012-02-20 07:39 AM)

Re: Never before has so little power been made from so much displacement!

dsycks wrote:
Marc wrote:

this will spin it's internals like it's traveling 140 to 160mph max.

You have options to cool this thing with more than air? Maybe adapt a diff cooler to add some capacity and rid some heat at the same time?

PS- I know a carny wheel setup is not fitting with the cars swagger but I really do dig the whimsy it would add. Not advocating for it, just a comment from the sidelines.

cooling is more complicated than just putting Klotz oil in there. that stuff will put up to some seriously high temperatures and keep everything happy.

it's also seeing quite a bit less torque than it's rated for so it should help with the temperature issues.

1,117 (edited by Marc 2012-02-23 06:49 PM)

Re: Never before has so little power been made from so much displacement!

parts came in today:

http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0125.jpg
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0126.jpg

it's smaller than i expected, but that's good!

for what it's worth, the 3000GT makes 201 lb*ft and has a 1st gear of 3.071 so it sees 617lb*ft in the stock application. we're a bit close to that, but we should be alright.

and if anyone has a 3000GT transmissiona laying around, i could use the end of the shaft that goes in that box for it's spline.

Thanks!

1,118

Re: Never before has so little power been made from so much displacement!

Frankly, I'm amazed at the number of parts you have or have bought for this thing. Simply staggering.

Notwithstanding:
Awesome.
You.

1,119

Re: Never before has so little power been made from so much displacement!

Spank wrote:

Frankly, I'm amazed at the number of parts you have or have bought for this thing. Simply staggering.

Notwithstanding:
Awesome.
You.

they don't all end up in the vehicle, but they'll end up in future projects.

the problem is sometimes you can't get proper dimensions without having the thing in your hands

Re: Never before has so little power been made from so much displacement!

Marc wrote:

they don't all end up in the vehicle, but they'll end up in future projects.

the problem is sometimes you can't get proper dimensions without having the thing in your hands

I read this as "they'll end up furniture projects".  Which would also be cool...  Haldex as a foot stool...

A&D: 2011 Autobahn, 2012 Gingerman, 2012 Road America, 2012 Autobahn II, 2013 Gator-O-Rama (True 24!)
Sir Jackie Stewart's Coin Purse Racing
2013 Chubba Cheddar Enduro - Organizer's Choice, 2014 Doing Time in Joliet
http://www.facebook.com/#!/SirJackieSte … urseRacing

Re: Never before has so little power been made from so much displacement!

I'll definitely want to write up the full story of the Radial MR2 for Car and Driver after the race, so please shoot many photographs of the current round of the project.

1,122

Re: Never before has so little power been made from so much displacement!

Judge Phil wrote:

I'll definitely want to write up the full story of the Radial MR2 for Car and Driver after the race, so please shoot many photographs of the current round of the project.

no problem. i conveniently seperated the picture directories:

phase 1: http://www.frankensteinmotorworks.com/AirplaneMR2/

phase 2: http://www.frankensteinmotorworks.com/A … R2/phase2/

as always you're welcome to use any of the pictures in an article you write in exchange for sending me a link to the article.

Phase 3 will be replacing the radial with a turboshaft smile

Marc

1,123

Re: Never before has so little power been made from so much displacement!

Do we have an mechanical engineer in the house? i need some math smile

I have to add a flange to the 3000GT shaft and i have to cut off the splined end to shorten it. from what i can see, just machining a keyway in the shaft won't be enough. i can't find the math on using a taper-lock bushing instead.

The shaft is 28mm in OD and the load is 600lb*ft and may as well be a reciprocating load.

unfortunately i can't just weld the assembly together because it would burn up the seal i have to install. even if i'm willing to make it  impossible to dissemble.

1,124

Re: Never before has so little power been made from so much displacement!

Do you still have Gary's email that I gave you prior?

If not it is most likely in one of the recent emails we have shared or I can just get it for you...

Daniel Sycks
Muttonheads!, nee Focke-eWe190 85-86-87-88 GTI
A Division of Cosworthless Racing. Sponsored by Marlburro!
http://www.facebook.com/pages/Muttonhea … 7122228200

1,125

Re: Never before has so little power been made from so much displacement!

sorry about the lack of updates guys. i was in brazil last week (see here for pics: http://forums.24hoursoflemons.com/viewt … pid=139079 )

but anyways, i had time this evening to check out some of my decisions i made just before leaving. the news is good:

so i took off the tailshaft housing on the GT3000 transfer case and i put the thing in place. there's enough room in the body for everything:

http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0368.jpg

then, i thought a bit about the torque going through that shaft and figured i did not want a keyed coupler. so i doug through the pile of transmission parts i keep around for such occasions and i ran across an Toyota MR2 E153 output shaft (these get replaced when you change the final drive on them) and an overdrive gear that matches the spline. the spline is a very snug fit, probably .0002" interference fit or so and the neat thing is it has a perfect seal diameter right there also. it's actually a bearing diameter, but it'll work just fine.

http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0369.jpg

http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0371.jpg

so the plan this week is to merge the GT3000 shaft with the E153 output shaft, modify the tailshaft housing to hold a seal and everything. then i'll make a flange to weld onto that gear to hold a rubber guibo. a mating guibo mount will go on prop hub and that part of the equation will be done. the gt3000 box will be held with a bracket that goes to the old motor mount locations.



Then, the next part of the equation got a bit simpler.
http://frankensteinmotorworks.com/AirplaneMR2/phase2/IMG_0370.jpg

that's right, that's a goldwing 1800 final drive.

I build a short driveshaft between the GT3000 box and the goldwing final drive and mate the input of the final drive with the remains of the angry hamster box back plate. no more reduction there, just a pair of bearings to hold the old clutch in place. that way all the hydraulics still work (well, i still need to adjust the throw distance for full disengagement, but that's trivial.)

the only part i don't have and i need is a goldwing driveshaft to snag the proper spline that the box needs... off to e-bay smile

WOO!